CET-Metal Finishing.pdf

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EEM-TRP Assessment

Report

Volume IMETAL FINISHING

June 20, 1996

Prepared by:Energy and Environment Center Staff

in Conjunction with CAMP, Inc. Staff of

Cleveland, Ohio

For:The Energy, Environment, and Manufacturing

Technology Reinvestment ProjectEnergy and Environment Center

Industrial Technology InstituteAnn Arbor, Michigan 48106

The NIST Manufacturing

Extension Partnership alongwith the DOE Office of Indus-trial Technologies, and EPA's Design for the Environment group and EPA's Office of Research & Development areresponsible for creating thecoalition that successfullycompeted for TRP funding. Inaddition, these organizationsare important in terms of providing outreach and dis-semination of EEM deliverables to industry and government. Together, theseorganizations have a widevariety of programs targeted at manufacturers to improveenergy efficiency, environmen-tal performance, as well asmanufacturing process effi-ciency and technology access.

EEM-TRP Project

Foreword

All the assessments were well received, but implementation will take time.

Providing the report is only the first step to saving the customer money. Thecustomer must implement the recommendations listed in the report in orderto achieve the savings. All of the customers had a good understanding of what the next step was in order to achieve the recommended savings. Thespeed at which the customer acted on implementing the recommendation ismixed. Some customers start making changes based on the recommendationsimmediately, but many customers take upwards of a year to start. While an

assessment can take place any time during the year, many companies do notschedule money for such improvements until the beginning of their next fiscalyear. We found that many customers stated that the recommendations were

excellent, but the implementation projects would have to be submitted forapproval for the next fiscal year. The assessment team should keep in

contact with the customers during this period to provide implementationassistance and to help define projects.

Reports included in this volume were first edited to remove proprietaryinformation, such as company name, geographical location, plant layout

diagrams, and brand names. The genericized chapters were then submittedto the companies for approval to publish. Some reports were not released forinclusion in the given format. In these cases, recommendations have been

omitted. Note that the assessment reports included in this volume are onlysummaries of the actual reports, and generally, include less than one third of

the information provided to the customers.

INTRODUCTION....................................................................................................................................................... 1

COMPANY A.............................................................................................................................................................. 9

RECOMMENDATIONS...................................................................................................................................................... 91 Recycle Rinse Tank Water..................................................................................................................................... 9

2 Upgrade Motors and Drives ............................................................................................................................... 13

3 Increase Wash Bath Life ..................................................................................................................................... 14

4 Upgrade Lighting System.................................................................................................................................... 18

5 Cover Heated Tanks with Insulating Balls.......................................................................................................... 21

6 Upgrade Compressed Air System........................................................................................................................ 23

7 Improve Boiler Efficiency.................................................................................................................................... 27

OPPORTUNITIES............................................................................................................................................................ 321 E-coat Rack Cleaning ......................................................................................................................................... 32

2 Improve Plating Performance by Using Deionized Water.................................................................................. 32

3 Improve Material Flow Through Shipping & Receiving..................................................................................... 33

COMPANY B............................................................................................................................................................ 34

RECOMMENDATIONS.................................................................................................................................................... 351 Upgrade Motors and Drives ............................................................................................................................... 35

2 Upgrade Lighting Systems .................................................................................................................................. 37

4 Insulate Steam Pipes ........................................................................................................................................... 42

5 Improve Power Factor........................................................................................................................................ 43

6 Reduce Water Use in Paint Line ......................................................................................................................... 45

7 Reduce Plating Drag-out .................................................................................................................................... 46

OPPORTUNITIES............................................................................................................................................................ 481 Implement a Pull System ..................................................................................................................................... 48

COMPANY C............................................................................................................................................................ 51

RECOMMENDATIONS.................................................................................................................................................... 511 Upgrade Lighting Systems .................................................................................................................................. 51

3 Improve Boiler Efficiency.................................................................................................................................... 55

4 Improve Barrel E-Coat Oven Efficiency ............................................................................................................. 58

6 Improve E-Coat Rack Stripping .......................................................................................................................... 63

7 Extend Life of Alkaline Cleaners (Rack A).......................................................................................................... 65

OPPORTUNITIES............................................................................................................................................................ 681 Sludge System...................................................................................................................................................... 68

2 Drag-out Reduction on Rack A ........................................................................................................................... 69

3 Reduce Customer Reject, Sorting & Scrap.......................................................................................................... 70

COMPANY D............................................................................................................................................................ 73

RECOMMENDATIONS.................................................................................................................................................... 731 Upgrade Lighting Systems .................................................................................................................................. 73

3 Upgrade Compressed-Air System ....................................................................................................................... 77

4 Alternative Rack Cleaning Method ..................................................................................................................... 82

5 Improve Power Factor........................................................................................................................................ 86

OPPORTUNITIES............................................................................................................................................................ 881 Conveyor Cleaning.............................................................................................................................................. 88

2 Automating Solution Removal............................................................................................................................. 88

3 Reducing Gap between Jobs on Conveyor.......................................................................................................... 89

COMPANY E............................................................................................................................................................ 91

RECOMMENDATIONS.................................................................................................................................................... 911 Purchase and install a localized switching capacitor bank. ........ .......... ......... ......... .......... ......... ......... ............... 91

2 Retrofit electric ovens with gas burners or purchase used gas ovens................................................................. 93

3 Process and Cooling Water Separation .............................................................................................................. 95

OPPORTUNITIES............................................................................................................................................................ 961 Make Shop Air Pressure 80 psi ........................................................................................................................... 96

2 Insulate Boiler Steam Lines and Chiller Water Lines ........... .......... ........... .......... ........... .......... ............... .......... . 96

3 Combine Condensate Return and Boiler Feedwater........................................................................................... 96

4 Consider Several Labor-Saving Improvements in Masking and Part Preparation............................................. 96

5 Cool Parts Outside Ovens with Doors Closed .................................................................................................... 97

APPENDIX A ............................................................................................................................................................ 99

APPENDIX B (MOTOR EFFICIENCIES).......................................................................................................... 151

10%15%

CompanyOverhead

Direct Labor

EnvironmentalServices

Material

Outside Services

ProductionOverhead

Utilities

1Aqualogic, Inc., North Haven, CT.

= × × × ×

( ) ( )

3North American Combustion Handbook, Volume I, Third Edition, 1986, pg. 126

4According to a McMaster-Carr representative.

= × × ×

( ) ( )

= × −

5Interpolated from Figure 6-11, “The Control of Boilers”; Dukelow, Sam; Instrument Society of America, 1986.

× −

6Based on manufacturers' sales literature.7Based on discussions with boiler adjustment contractors

( ) ( )

ES EU FR

kWh yr

390 871 0 10

39 087

NCS CS AMC

$2, $206

$2,284/

9 It is assumed that there will be no increase in steam usage, since the evaporators are now used only on weekendsand now will be used to evaporate lesser quantities of water over longer time periods.10 Air knives can be purchased from Exair Corporation, Cincinnati, OH (513)671-3322.

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